Ceramic matrix composite airfoil repair
AssigneeGeneral Electric Company
InventorsHerbert Chidsey Roberts, Glenn Curtis Taxacher
Life of this patent
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Abstract
Methods for repairing composite components are provided. For instance, one exemplary method includes machining an interlocking feature into an existing component. A replacement material or core having an interlocking feature complementary to the interlocking feature of the existing component is then joined with the component. The interlocking features interlock to form a joint. The joint is then overlaid with one or more plies to rebuild the outer surface of the component and seal the joint. A bonding process can be used to chemically bond the newly joined parts together. Repaired composite components are also provided.
Claims10
A method for repairing a component having a damaged region, the component formed from a composite material and defining a span length that extends from a first end of the component to a second end of the component, and a reference line that is defined midway between the first end and the second end, the damaged region being closer to the second end than the first end, wherein the component is an airfoil for use in a gas turbine engine, the method comprising:
- joining a replacement material with the component, the replacement material having a tip end, a connection end, a leading edge, and a trailing edge, wherein the component comprises an interlocking feature and the connection end of the replacement material comprises an interlocking feature complementary to the interlocking feature of the component, wherein when the replacement material is joined with the component, the interlocking features of the replacement material and the component interlock to form a joint that defines a joint width and a joint length, the joint width being perpendicular to the joint length and the joint length spanning a width of the component;
- overlaying the joint with a plurality of plies, wherein overlaying the joint comprises laying a first ply over the joint on a pressure side of the airfoil and laying a second ply over the joint on a suction side of the airfoil;
- and
- bonding the component with the replacement material and bonding the plurality of plies with the component and the replacement material;
- wherein the joint is only between the reference line and the first end of the component;
- wherein the first ply extends beyond the leading edge of the replacement material;
- wherein overlaying the joint with a plurality of plies comprises laying one or more ply layers on the pressure side of the airfoil and laying one or more ply layers on the suction side of the airfoil, wherein the number of ply layers on the pressure side of the airfoil does not equal the number of ply layers on the suction side of the airfoil.
Dependencies are inferred from the claim text.